| Date | Assembly | Instruction | Part | Description | Links |
|---|---|---|---|---|---|
| 10/18/2011 | Wing | W03 | W04 | Cleaned labels and glue off of vatious parts. | Photos Shop-Video |
| 10/18/2011 | Wing | W03 | W04-01R | W04-01R Right Hand Aileron Skin - Layed out shape and did rough cut. Started filing to final shape and size. | Photos Shop-Video |
| 10/19/2011 | Wing | W03 | W04-01R | W04-01R Right Hand Aileron Skin - Filed end to final shape and dimentions per the plans. Cut openings for Drive Rib and Counterbalance Assembly. Deburred all edges. | Photos Shop-Video |
| 10/19/2011 | Wing | W03 | W04-01L | W04-01L Left Hand Aileron Skin - Layed out shape for end cut. Cut end and filed to final shape and dimentions per the plans. Cut openings for Drive Rib and Counterbalance Assembly. Deburred all edges. | Photos Shop-Video |
| 10/20/2011 | Wing | W03 | W04-02 W04-03 W04-04 | W04-02 -03 Aileron Ribs - Deburred edges and adjusted flanges to 90 degree angle. W04-04 Aileron Drive Plate - Drilled #40 pilot holes and polished/ deburred edges with scoth brite wheel. | Photos Shop-Video |
| 10/20/2011 | Wing | W03 | W04-05R W04-05L W04-06R W04-06L | W04-05R -05L Right and Left Hand Aileron Drive Rib Assemblies - Drilled #40 pilot holes. Updrilled #30 holes. Also updrilled to 3/16th the attachment hole. Rivetted the assembly per the plans. W04-06R -06L Aileron Hinge Halves - Cut the hinge halves to length per the plans. Drilled the #40 pilot holes per the plans. Used the yard stick gig to locate the holes. Skipped the holes that were at different locations. Those holes were located and drilled by hand. | Photos Shop-Video |
| 10/22/2011 | Wing | W03 | W04-08 | W04-08 Aileron Counterbalance - Used a hack saw to cut the lead diagonally to the shape per the plans. | Photos Shop-Video |
| 10/22/2011 | Wing | W03 | W04-11 W04-12 W04-09 | W04-11 and W04-12 - Angles - Cut from angle stock to length and shape per the plans. Drilled #40 pilot holes and Updrilled #30 holes. Deburred all holes and edges. Rivetted the angles together to create W04-09 Channel Assembly. | Photos Shop-Video |
| 10/27/2011 | Wing | W03 | W03-03 | W03-03 Counterbalance Assembly - Started the assembly. First aligned W04-03 Aileron Rib with W04-07 Counterbalance Plate and drilled #40 pilot holes for that half of the assembly. Then aligned W04-02 Aileron Rib with another W04-07 Counterbalance Plate and drilled the #40 pilot holes for that half. Then joined the two haves together with the W04-09 Channel. I used the two pervious assembled halves as a guide to locate and drill the #40 pilot holes. | Photos Shop-Video |
| 10/28/2011 | Wing | W03 | W04-09 | W04-09 Channel Assembly - Made an assembly to replace the one that yesterday had wrong holes drilled trying to make the W03-03 Counterbalance Assembly. | Photos Shop-Video |
| 10/28/2011 | Wing | W03 | W03-03 | W03-03 Counterbalance Assembly - Started the second assembly. First aligned W04-03 Aileron Rib with W04-07 Counterbalance Plate and drilled #40 pilot holes for that half of the assembly. | Photos Shop-Video |
| 10/28/2011 | Wing | W03 | W03-03 | W03-03 Counterbalance Assembly - For the second assembly aligned W04-02 Aileron Rib with another W04-07 Counterbalance Plate and drilled the #40 pilot holes for that half. Then joined the two haves together with the W04-09 Channel. I used the two pervious assembled halves as a guide to locate and drill the #40 pilot holes. Updrilled all holes to #30 for both W03-03 Counterbalance Assemblies. | Photos Shop-Video |
| 10/29/2011 | Wing | W03 | W03-03 | W03-03 Counterbalance Assembly - Deburred all edges and holes on one of the assemblies. Started drilling and updrilling the holes through the lead for the one assembly. | Photos Shop-Video |
| 10/31/2011 | Wing | W03 | W0-03 | W03-03 Counterbalance Assembly - Finnished drilling holes through the lead on the first assembly. Deburred holes on counterbalance plate. Riveted assembly per the plans. Installed bolts and torqued nuts to 25 in/lbs. One assembly is completed. | Photos Shop-Video |
| 10/31/2011 | Wing | W03 | W03-03 | W03-03 Counterbalance Assembly - Deburred all edges and holes on the second assembly. Drilled and updrilled all the holes through the lead for the second assembly. | Photos Shop-Video |
| 11/1/2011 | Wing | W03 | W03-03 | W03-03 Counterbalance Assembly - Deburred holes for bolts. Riveted assembly per the plans. Installed bolts and torqued nuts to 25 in/lbs. The second assembly is complete. | Photos Shop-Video |
| 11/1/2011 | Wing | W03 | W03-01R W03-01L | W03-01R Right Hand Aileron - Laid out holes to be drilled in the skin. Drilled #40 pilot holes. W03-01L Left Hand Aileron - Laid out holes to be drilled in skin. | Photos Shop-Video |
| 11/2/2011 | Wing | W03 | W03-01R W03-01L | W03-01L Left Hand Aileron - Drilled #40 pilot holes. Debured holes for both Right and Left hand skins. W03-01R Right Hand Aileron - Started drilling #40 pilot holes for the aileron ribs. | Photos Shop-Video |
| 11/3/2011 | Wing | W03 | W03-01R | W03-01R Right Hand Aileron - Fitted Counterbalance Assembly and drilled #40 pilot holes. Continued drilling #40 pilot holes for aileron ribs. Aligned hinge and drilled #40 pilot holes only in locations for ribs and counterbalance assembly. Also updrilled to #30 holes for hinge only at rib and counterbalance locations. Updrilled to #30 holes on forward and top sides of aileron. | Photos Shop-Video |
| 11/4/2011 | Wing | W03 | W03-01R | W03-01R Right Hand Aileron - Drilled #40 pilot holes on bottom side of aileron. Updrilled to #30 holes on bottom side of aileron. Cut and trimmed angle on 2X4 wood to use as backing for drilling hinge holes. Removed all celcos. Removed all ribs. Sandwiched aileron skin between 2X4 and hinge spacing board and clamped to the work table. Drilled into the 2X4 at previously drilled locations and celcoed in place. | Photos Shop-Video |
| 11/4/2011 | Wing | W03 | W03-01R | W03-01R Right Hand Aileron - Drilled #40 pilot holes and updrilled #30 holes for all of hinge. Removed all clecos and deburred all holes. Re-assembled with clecos. Did all rivets per the plan except a couple that are close to counterbalance assembly. These will need a special tool to get done correctly. I need to investigate how I will do these last rivets. | Photos Shop-Video |
| 11/6/2011 | Wing | W03 | W03-01R | W03-01R Right Hand Aileron - Fabricated a wedge of aluminium to allow riveting the hard to reach rivets around the counterbalance assembly. Riveted the remaining rivets. Started forming the tip for the right hand aileron. | Photos Shop-Video |
| 11/7/2011 | Wing | W03 | W03-01R | W03-01R Right Hand Aileron - Finished forming the tip. Drilled #40 pilot holes and updrilled #30 holes for the tip. Deburred and cleaned the tip and skin. Riveted the tip in place on the aileron. The right hand aileron is now complete. | Photos Shop-Video |
| 11/8/2011 | Wing | W03 | W03-01L | W03-01L Left Hand Aileron - Trimmed Skin just below the counterbalance assembly to allow assembly to fit properly in the skin. Placed ribs in the skin. Drilled #40 pilot holes in the ribs using the pilot holes in the skin for location. Started up-drilling pilot holes to #30 holes. | Photos Shop-Video |
| 11/9/2011 | Wing | W03 | W03-01L | W03-01L Left Hand Aileron - Finnished updrilling all #30 holes. For the hinge first drilled #40 pilot holes and then updrilled to #30. Deburred all holes. Riveted the Aileron per the plans. | Photos Shop-Video |
| 11/10/2011 | Wing | W03 | W03-01L | W03-01L Left Hand Aileron - Fitted tip to aileron. Drilled #40 pilot holes. Updrilled #30 holes. Deburred all holes and riveted tip to aileron per the plans. | Photos Shop-Video |